Wet granulation for manufacture of thermal insulation material

ABSTRACT

An appliance cabinet includes a structural envelope having an exterior surface and an interior surface that defines an insulating cavity, wherein the insulating cavity defines an at least partial vacuum. A plurality of silica-based agglomerates are disposed within the insulating cavity, wherein each agglomerate of the plurality of silica-based agglomerates includes silica-based powder insulation material that is water-densified and is at least substantially free of a material binder. A secondary insulation material is disposed within interstitial spaces defined between the plurality of silica-based agglomerates, wherein the plurality of silica-based agglomerates defines an interior structure that resists inward compressive forces exerted as a result of the at least partial vacuum defined within the insulating cavity.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent applicationSer. No. 17/545,026 filed Dec. 8, 2021, which is a continuation of U.S.patent application Ser. No. 17/042,300 filed Sep. 28, 2020, now U.S.Pat. No. 11,226,153, which is a national stage of PCT/US2018/026881filed Apr. 10, 2018, all of which are entitled WET GRANULATION FORMANUFACTURE OF THERMAL INSULATION MATERIAL, the entire disclosures ofwhich are hereby incorporated herein by reference.

FIELD OF THE DEVICE

The device is in the field of insulation systems for use in variousappliances, and more specifically, a silica-based insulation system thatis formed into agglomerates or aggregates for providing internalstructural support within various vacuum insulated structures.

SUMMARY

In at least one aspect, a method for forming a granulated insulationmaterial for use in an appliance cabinet includes combining a powderinsulation material and water to define a partially wetted insulationmaterial. The wetted insulation material is mixed to define a pluralityof wet insulation granules. The water is evaporated from the wetinsulation granules to define a plurality of dry insulationagglomerates, wherein the plurality of wet insulation granules and theplurality of dry insulation agglomerates are substantially the samesize.

In at least another aspect, a method for forming a vacuum insulatedstructure for use in an appliance includes combining a silica-basedpowder insulation material and water to define a partially wettedinsulation material. The wetted insulation material is mixed to define aplurality of wet insulation granules. The water from the wet insulationgranules is evaporated to define a plurality of dry insulationagglomerates. The dry insulation agglomerates are disposed within aninsulating cavity defined within a structural envelope. Air is expressedfrom the insulating cavity to define an at least partial vacuum withinthe insulating cavity.

In at least another aspect, an appliance cabinet includes a structuralenvelope having an exterior surface and an interior surface that definesan insulating cavity, wherein the insulating cavity defines an at leastpartial vacuum. A plurality of silica-based agglomerates are disposedwithin the insulating cavity, wherein each agglomerate of the pluralityof silica-based agglomerates includes silica-based powder insulationmaterial that is water-densified and is at least substantially free of amaterial binder. A secondary insulation material is disposed withininterstitial spaces defined between the plurality of silica-basedagglomerates, wherein the plurality of silica-based agglomerates definesan interior structure that resists inward compressive forces exerted asa result of the at least partial vacuum defined within the insulatingcavity.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of an appliance that incorporates anaspect of the granulated insulation material;

FIG. 2 is a cross-sectional view of the appliance of FIG. 1 , takenalong line II-II;

FIG. 3 is a schematic diagram illustrating a method for forming wetinsulation granules that can be later converted into an aspect of thegranulated insulation material for use in vacuum insulated structures;

FIG. 4 is a schematic diagram illustrating a process for converting thewet insulation granules into the granulated insulation material;

FIG. 5 is a cross-sectional view of an aspect of a dry insulationagglomerate;

FIG. 6 is a cross-sectional view of an aspect of a dry insulationaggregate formed of multiple insulation materials;

FIG. 7 is a cross-sectional view of an aspect of a dry insulationaggregate formed of multiple insulation materials;

FIG. 8 is a linear flow diagram illustrating an aspect of a method forforming a granulated insulation material for use in an appliancecabinet; and

FIG. 9 is a linear flow diagram for a method of forming a vacuuminsulated structure for use in an appliance.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1 . However, itis to be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

With respect to FIGS. 1-4 , reference numeral 10 generally refers to agranulated insulation material that can be used within a cabinet 12 foran appliance 14 and typically within vacuum insulated structures 16 forvarious residential and commercial appliances and fixtures. According tovarious aspects of the device, the cabinet 12 can include a structuralenvelope 18 having an exterior surface 20 and an interior surface 22that defines an insulating cavity 24. The insulating cavity 24, uponformation of the cabinet 12, can define an at least partial vacuum 26. Aplurality of silica-based agglomerates 28 and/or silica-based aggregates30 that make up the granulated insulation material 10 can be disposedwithin the insulating cavity 24. Where the silica-based agglomerates 28are used, each agglomerate 28 of the plurality of silica-basedagglomerates 28 includes a silica-based powder insulation material 32that is water-densified and is at least substantially free of a materialbinder. A secondary insulation material 34 can be disposed withininterstitial spaces 36 that are defined between the silica-basedagglomerates 28, and where used, the silica-based aggregates 30.

The granulated insulation material 10 that can be made up of a pluralityof silica-based agglomerates 28 and/or aggregates 30 defines an interiorstructure 50 that resists inward compressive forces 52 that may beexerted as a result of the at least partial vacuum 26 defined within theinsulating cavity 24. In this manner, when the at least partial vacuum26 is formed within the insulating cavity 24, the pressure differentialbetween the insulating cavity 24 and areas external to the structuralenvelope 18 generate inward compressive forces 52 that may result indeformation, aesthetic demarcation and other types of deflection thatcan be visible on the exterior surface 20 of the structural envelope 18.The use of the granulated insulation material 10 having at least one ofthe aggregates 30 and agglomerates 28 substantially occupies theinsulating cavity 24 and serves to engage the interior surface 22 of thestructural envelope 18 and resist the inward compressive forces 52generated by the at least partial vacuum 26.

Referring now to FIGS. 5-7 , the granulated insulation material 10 caninclude silica-based agglomerates 28 that are exemplified in FIG. 5 .These silica-based agglomerates 28 are typically made of thesilica-based powder insulation material 32. The silica-type material caninclude, but is not limited to, precipitated silica, fumed silica,combinations thereof and other similar silica-based materials. Theseagglomerates 28 are generally free of additional insulating materialswith the possible exception of an insulating gas 60 that may be allowedto infiltrate and replace air within various cavities and spaces definedwithin the silica-based agglomerate 28. The aggregates 30 that may format least a portion of the granulated insulation material 10 typicallyinclude additional insulating particles in the form of secondarycomponents 62. These secondary components 62 can be in the form of glassmicrospheres 64, perlite microspheres 66, various opacifiers,combinations thereof, and other similar insulating components thatsupplement and cooperate with the powder insulation material 32. The useof these additional secondary components 62 can serve to increase thecompressive strength of each particle of the granulated insulationmaterial 10. These secondary components 62 of the granulated insulationmaterial 10 can also serve to increase the insulating performance of thegranulated insulation material 10. The secondary components 62 can alsoact as an anchor material that assists in maintaining the integrity ofeach aggregate 30 of the granulated insulation material 10. While thesilica-based powder insulation material 32 is held together as a resultof the water-based densification process, the addition of the secondarycomponents 62 can further add to the retaining properties of eachaggregate 30. The process for forming the various agglomerates 28 andaggregates 30 of the granulated insulation material 10 will be describedmore fully below.

Referring again to FIG. 2 , when the granulated insulation material 10,made up of the agglomerates 28, is disposed within the insulating cavity24, each agglomerate 28 of the plurality of silica-based agglomerates 28is in direct engagement with at least one adjacent agglomerate 80 of theplurality of silica-based agglomerates 28. In this manner, the interiorstructure 50 defined by the granulated insulation material 10 extendssubstantially through the insulating cavity 24 and the variousagglomerates 28 support one another to provide the interior structure 50for maintaining a consistent width 82 of the various walls 84 for thestructural envelope 18 of the cabinet 12. The same is true where thegranulated insulation material 10 is made up of the aggregates 30. Ineither instance, the granules of the granulated insulation material 10form the interior structure 50. These granules can include eitheragglomerates 28, aggregates 30, or both.

As discussed previously, at least a portion of the granulated insulationmaterial 10 can be in the form of a silica-based aggregate 30 having atleast one of the secondary components 62 included therein. Again, thesesecondary components 62 can include, but are not limited to, perlitemicrospheres 66, hollow and/or solid glass microspheres 64, at least oneopacifier, combinations thereof, and other similar insulating materials.In various aspects of the device, the agglomerates 28 and aggregates 30cooperate to define the interior structure 50.

Referring again to FIG. 2 , the secondary insulation material 34 that isincluded within the insulating cavity 24 can be in the form of at leastone of a silica-based material, an insulating gas 60, perlitemicrospheres 66, glass microspheres 64, at least one opacifier, glassfiber, combinations thereof, and other similar insulating materials thatcan be used to occupy the various interstitial spaces 36 defined betweenthe granules of the granulated insulation material 10. Where anopacifier is used, the opacifier can include, but is not limited to,carbon black, silicon carbide, zinc oxide, rice husk ash, and titaniumoxide, combinations thereof and other similar materials that reduceradiative thermal conductivity.

According to various aspects of the device, the various agglomerates 28and aggregates 30 of the granulated insulation material 10 can be formedduring a binding process 100 that includes the use of water 102 as thebinding agent. Typically, only water 102 is used as the binding agent.During this binding process 100, the silica-based powder insulationmaterial 32 and any secondary components 62 are combined together andwater 102 is added to the silica-based powder insulation material 32 toform a wetted insulation material 104 that defines a plurality of wetinsulation granules 106. These wet insulation granules 106 are thendried to form dry insulation agglomerates 28, and, where the secondarycomponents 62 are used, dry insulation aggregates 30. These aggregates30 and agglomerates 28 can be held together as a result of the clumpingtendency of the silica-based powder insulation material 32 that utilizesthe Van der waals force that can tend to cause individual particles tocling to one another. By forming the silica-based powder insulationmaterial 32 into the aggregates 30 and agglomerates 28, the individualgranules of the granulated insulation material 10 have added compressivestrength to resist the inward compressive forces 52 generated by the atleast partial vacuum 26 defined within the insulating cavity 24. Theaggregates 30 and agglomerates 28 of the granulated insulation material10 also provide better flowability for disposing the granulatedinsulation material 10 within the insulating cavity 24 of the structuralenvelope 18. The granulated insulation material 10 tends to pour or flowwith a much greater consistency and efficiency as compared topowder-based insulation materials. Accordingly, the use of thegranulated insulation material 10 provides for a more efficient andconsistent filling of the insulating cavity 24 of the structuralenvelope 18 and also provides for less waste when compared to pouring ofpowder-based insulation materials.

Additionally, the use of water 102 as the binding agent provides for anenvironmentally responsible and reusable substance to serve as thebinding agent for the aggregates 30 and agglomerates 28. Moreover, theuse of water 102 in combination with the Van der waals forces used tohold the aggregates 30 and agglomerates 28 together can be used as asubstantially temporary binding agent. The water 102 can be added to thesilica-based powder insulation material 32 and then removed during aheating process or drying process where substantially all of the water102 within the aggregates 30 and agglomerates 28 is removed. Again, thisprocess for forming the various aggregates 30 and agglomerates 28 of thegranulated insulation material 10 will be described more fully below.

Referring now to FIGS. 1-4 and 8 , having described various aspects ofthe granulated insulation material 10 and the agglomerates 28 andaggregates 30 that make up this granulated insulation material 10, amethod 400 is disclosed for forming the granulated insulation material10 for use in an appliance cabinet 12. According to the method 400, step402 includes combining a powder insulation material 32 and water 102, oranother binder, to define a partially wetted insulation material 104. Asdiscussed above, the powder insulation material 32 can be defined by thesilica-based powder insulation material 32 as well as various secondarycomponents 62 that are added to the silica-based powder insulationmaterial 32. The identity of the granulated insulation material 10 ashaving aggregates 30 and agglomerates 28 can depend upon whether thesecondary components 62 are added to the silica-based powder insulationmaterial 32. In step 402 where the powder insulation material 32 iscombined with water 102, the amount of water 102 is typically sufficientto only partially wet the powder insulation material 32 to form clumpsof the powder insulation material 32. These clumps can take the form ofthe wetted insulation material 104. In this step 402, if a slurry isformed, it is typically indicative of too much water 102 being added.The goal of this step 402 is to provide enough water 102 to the powderinsulation material 32 to form a generally granular composition of onlyslightly wetted clumps of the powder insulation material 32.

According to the method 400, as exemplified in FIGS. 1-4 and 8 , step404 includes mixing the wetted insulation material 104 to define aplurality of wet insulation granules 106. This mixing step 404 can beperformed in a mixer 120, on rollers, within a drum, or within anothersimilar mixing apparatus. The mixing step 404 can also use variousagitators, vibrating mechanisms, impellers, and other mixing agents forconverting the partially wetted insulation material 104 into theplurality of wet insulation granules 106. The size of the wet insulationgranules 106 and the final dry granules 86 can be determined based uponvarious factors. These factors can include, but are not limited to, thesequence and parameters of the mixing operation 122, the size of themechanism performing the mixing, the amount of water 102 added to thepowder insulation material 32, the amount of secondary components 62, ifany, incorporated within the powder insulation material 32, and othersimilar factors. The sequence and parameters of the mixing operation 122can include the length of mixing, the speed of the mixing apparatus,modifications and modulations of the mixing speed during performance ofthe mixing operation 122, the amount of the wet insulation granules 106included within the mixing apparatus, combinations thereof, and othersimilar mixing parameters.

Referring again to FIGS. 1-4 and 8 , the method 400 also includes a step406 of evaporating the water 102 from the wet insulation granules 106 todefine a plurality of dry insulation agglomerates 28. As discussedabove, where the secondary components 62 are included within the powderinsulation material 32, performing this evaporating operation 112 willbe used to define a plurality of aggregates 30. This evaporating step406 can be performed through various operations that can include, bakingthe wet insulation granules 106, placing the wet insulation granules 106within a dry or arid environment, various heating operations, dryingoperations using a decreased pressure environment or an at least partialvacuum, and other similar operations that can be used to evaporate water102 from the wet insulation granules 106.

Typically, as a result of this evaporating step 406, the plurality ofwet insulation granules 106 and the plurality of dry insulationagglomerates 28 (or aggregates 30) have a substantially similar size. Inthis manner, as water 102 is removed during this evaporating step 406,water 102 is evaporated from within each granule 86 of the granulatedinsulation material 10. The space previously occupied by water 102 maytend to form various air spaces or pores 130 defined within each granule86 of the granulated insulation material 10. According to variousaspects of the device, it is contemplated that some shrinkage of eachgranule 86 may occur as a result of the evaporating step 406.

As discussed above, the amount of water 102 included within the powderinsulation material 32 is substantially minimal such that each wetinsulation granule 106 includes a minimal amount of water 102 as atemporary binding agent. The various particles of the wetted insulationmaterial 104 and ultimately, the dry insulation agglomerates 28 and dryinsulation aggregates 30 are at least partially held together throughthe Van der waals force. It is also contemplated that trace amounts ofwater 102 may also be used to hold the various granules 86 of thegranulated insulation material 10 together. In this manner, the dryinsulation agglomerates 28 and/or dry insulation aggregates 30 caninclude no water 102 or can include small amounts of water 102.According to the various aspects of the device and aspects of thevarious methods, this process for forming the granulated insulationmaterial 10 can be formed using water 102 as the only additive to thepowder insulation material 32 and, where present, the secondarycomponents 62. Additionally, the evaporating step 406 of method 400 canbe accomplished in a manner that is free of material drying agents andusing only heat, a decreased pressure environment, an at least partialvacuum and/or latent evaporation of water 102 to form the dry form ofthe granulated insulation material 10.

According to various aspects of the device, the granulated insulationmaterial 10 formed according to method 400 can be used to form acomposite insulation material 140 that includes the dry insulationagglomerates 28 and/or dry insulation aggregates 30 in combination withthe secondary insulation material 34. In such an aspect of the device,the method 400 can include a step 408 that includes combining thegranulated insulation material 10 with the secondary insulation material34. As discussed previously, this secondary insulation material 34substantially occupies various interstitial spaces 36 that are definedbetween the granules 86 of dry insulation agglomerates 28 and/or dryinsulation aggregates 30 of the granulated insulation material 10. Onceformed, this composite insulation material 140 can be packaged fordelivery, moved to a separate location, or disposed within theinsulating cavity 24 of a structural envelope 18 for an appliance 14. Itis also contemplated that the granulated insulation material 10 can beused by itself as the insulating material for use within the insulatingcavity 24 of a structural envelope 18 for an appliance 14. The compositeinsulation material 140 can also be formed within the insulating cavity24 where the granulated insulation material 10 is first placed thereinand the secondary insulation material 34 is subsequently added to thegranulated insulation material 10.

Referring now to FIGS. 1-4 and 9 , a method 500 is also disclosed forforming a vacuum insulated structure 16 for use in an appliance 14.According to the method 500, a step 502 can include combining asilica-based powder insulation material 32 with water 102, or anotherbinder, to define a partially wetted insulation material 104. Asdiscussed previously, the amount of water 102 included within thesilica-based powder insulation material 32 is substantially minimal andsufficient to tend the silica-based powder insulation material 32 intoclumps that take the form of the wetted insulation material 104. The useof water 102 acts in combination with the Van der waals force toaccomplish greater clumping of the silica-based powder insulationmaterial 32. According to the method 500, step 504 includes mixing thewetted insulation material 104 to define a plurality of wet insulationgranules 106. As discussed above, this mixing step 504, similar to themixing step 404 for method 400, can include various mixing operations122 and sequences and parameters as well various mixing mechanisms foraccomplishing this step 504 of the method 500. According to the method500, step 506 includes evaporating the water 102 from the wet insulationgranules 106 to define a plurality of dry insulation agglomerates 28.The various evaporating operations 112 described herein may be used. Theamount of water 102 included within each wet insulation granule 106 issubstantially minimal such that only small amounts of water 102 willneed to be evaporated from each wet insulation granule 106 during theevaporating operation 112.

According to the method 500, step 508 can include disposing the dryinsulation agglomerates 28 and/or dry insulation aggregates 30 within aninsulating cavity 24 defined within a structural envelope 18. Asdiscussed above, the identity of the granulated insulation material 10as having agglomerates 28 or aggregates 30 can depend upon whether thesecondary components 62 of the powder insulation material 32 areincluded therein. Where the secondary components 62 are included, thismaterial is typically in the form of the dry insulation aggregates 30that include multiple materials, as discussed above. Additionally, thisstep 508 of disposing the dry insulation agglomerates 28 within theinsulating cavity 24 can also include disposing a secondary insulationmaterial 34 into the insulating cavity 24.

This secondary insulation material 34 can be premixed with thegranulated insulation material 10 and disposed as a single compositeinsulation material 140 into the insulating cavity 24. In variousaspects of the device, the secondary insulation material 34 can besubsequently disposed within the insulating cavity 24 and filteredbetween the granulated insulation material 10 to occupy the variousinterstitial spaces 36 defined between the aggregates 30 and/oragglomerates 28 of the granulated insulation material 10.

Once the insulating cavity 24 is substantially filled with thegranulated insulation material 10 and, where desired, the secondaryinsulation material 34, the structural envelope 18 can be sealed and airis expressed from the insulating cavity 24 to define an at least partialvacuum 26 within the insulating cavity 24 (step 510). This step 510 ofexpressing air forms the at least partial vacuum 26 that can result inthe inward compressive forces 52 that are exerted upon the exteriorsurface 20 of the structural envelope 18. In this manner, the pluralityof dry insulation agglomerates 28 and/or dry insulation aggregates 30define an interior structure 50 that resists these inward compressiveforces 52 exerted on the exterior surface 20 of the structural envelope18. The formation of the silica-based powder insulation material 32 intothe aggregates 30 and agglomerates 28 forms the interior structure 50that resists inward compression or deformation of the structuralenvelope 18 that may cause aesthetic demarcation and also thinning ofthe walls 84 of the structural envelope 18. Accordingly, the use of thegranulated insulation material 10 serves to maintain a substantial width82 or a thickness of the various walls 84 of the structural envelope 18.Additionally, the plurality of granules 86 of the granulated insulationmaterial 10 operating in a cooperative fashion serves to resist thisinward compression or deformation. The conglomeration of the pluralityof aggregates 30 and agglomerates 28 of the granulated insulationmaterial 10 operate in concert to resist this inward compressive force52 and also resist degradation of the various granules 86 of thegranulated insulation material 10.

Referring again to FIGS. 1-4 and 9 , the amount of water 102 by weightthat is used within step 502 for combining with the silica-based powderinsulation material 32 is typically less than an amount of thesilica-based powder insulation material 32 by weight. Accordingly, thewetted insulation material 104 includes substantially more silica-basedpowder insulation material 32 than water 102. Typically, the water 102is in an amount sufficient to cause clumping of the powder insulationmaterial 32 but insufficient to create a slurry or substantially wetmaterial.

According to the method 500, the evaporating step 506 can beaccomplished in a fashion substantially similar to that of step 406 frommethod 400 described above. Typically, the use of heat or aridenvironments will be used to accomplish this evaporating operation 112.It is contemplated that the use of blowing air can be used for assistingin the evaporation of the water 102.

According to various aspects of the device, the granulated insulationmaterial 10 described herein can be used within various appliances 14.These appliances 14 can include, but are not limited to, refrigerators,freezers, coolers, laundry appliances, dishwashers, ovens, smallappliances, water heaters, kitchen-type tools, and other similarresidential and commercial appliances and fixtures. The granulatedinsulation material 10 can also be used in structural cabinets 12,vacuum insulated panels, and other similar insulating materials.

Where the secondary insulation material 34 is an insulating gas 60, theinsulating gas 60 can be included within the insulating cavity 24 in amanner such that the insulating gas 60 infiltrates the interstitialspaces 36 defined between the granules 86 of the granulated insulationmaterial 10 and replaces air within these interstitial spaces 36. Thisinsulating gas 60 can also be disposed within the various pores 130defined within the granules 86 of the granulated insulation material 10.Accordingly, through the use of the granulated insulation material 10and one or more secondary insulation materials 34, substantially theentire insulating cavity 24 can be filled with materials havinginsulative properties greater than that of air or any one of thecomponents alone. In this manner, the granulated insulation material 10can serve as the base of a composite insulation structure that providesdesired insulative performance and also resists inward deflection of thestructural envelope 18 as a result of the at least partial vacuum 26defined within the insulating cavity 24. Moreover, the use of thegranulated insulation material 10 provides for an environmentallyconscious and reusable binder in the form of water 102 that can be usedto form the aggregates 30 and agglomerates 28 that make up thegranulated insulation material 10. The process for forming a granulatedinsulation material 10 can be formed without non-water binders andwithout the use of material drying agents to remove water 102 from eachgranule 86. In instances where water 102 is the binder and where anon-water material acts as the binder, the dry form of the granulatedinsulation material 10 can include small amounts of water 102 or thenon-water material to assist in maintaining the granular form of thevarious granules 86 of the granulated insulation material 10.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width 82 of the structures and/or members or connector orother elements of the system may be varied, the nature or number ofadjustment positions provided between the elements may be varied. Itshould be noted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above is merelyfor illustrative purposes and not intended to limit the scope of thedevice, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine ofEquivalents.

What is claimed is:
 1. A method for forming a flowable granulated insulation material, the method comprising steps of: combining a powder insulation material and a temporary binder to define a partially wetted insulation material; mixing the partially wetted insulation material to define wet insulation granules; and evaporating the temporary binder from the wet insulation granules to define dry insulation agglomerates, wherein the dry insulation agglomerates are substantially the same size as the wet insulation granules having the temporary binder.
 2. The method of claim 1, wherein the partially wetted insulation material contains an amount of temporary binder to define clumps of the powder insulation material.
 3. The method of claim 1, wherein the temporary binder is water.
 4. The method of claim 1, wherein the powder insulation material includes at least one of a silica-based material, perlite, glass microspheres and an opacifier.
 5. The method of claim 1, wherein the step of mixing the partially wetted insulation material includes mixing the partially wetted insulation material according to various mixing parameters, wherein the mixing parameters at least partially determine a granule size of the dry insulation agglomerates.
 6. The method of claim 1, wherein a granule size of the dry insulation agglomerates is at least partially determined by an amount of the temporary binder that is combined with the powder insulation material.
 7. The method of claim 1, further comprising a step of: combining the dry insulation agglomerates with a secondary insulation material, wherein the secondary insulation material substantially occupies interstitial spaces defined between the dry insulation agglomerates.
 8. The method of claim 1, wherein the step of evaporating the temporary binder from the wet insulation granules is performed by exposing the wet insulation granules to at least one of a decreased pressure environment and an arid environment.
 9. The method of claim 8, wherein the step of evaporating the temporary binder from the wet insulation granules is performed free of material drying agents.
 10. A method for forming an insulated structure, the method comprising steps of: combining a powder insulation material and temporary binder to define a partially wetted insulation material; mixing the partially wetted insulation material to define wetted insulation granules; evaporating the temporary binder from the wetted insulation granules to define dry insulation agglomerates; disposing the dry insulation agglomerates within a cavity defined within a structural envelope; and enclosing the cavity with the dry insulation agglomerates contained therein.
 11. The method of claim 10, wherein the step of enclosing the cavity includes a step of expressing gas from the cavity to define an at least partial vacuum within the cavity.
 12. The method of claim 10, wherein the dry insulation agglomerates define an interior structure that resists an inward compressive force exerted on the exterior of the structural envelope as a result of the at least partial vacuum defined within the cavity.
 13. The method of claim 10, wherein an amount of powder insulation material by weight in the partially wetted insulation material is greater than an amount of the temporary binder by weight in the partially wetted insulation material.
 14. The method of claim 10, wherein the powder insulation material includes at least one of a silica-based material, perlite, glass spheres, and an opacifier, and wherein the dry insulation agglomerates define composite aggregates.
 15. The method of claim 10, wherein the step of disposing the dry insulation agglomerates within the cavity includes disposing a secondary insulation material into the cavity, wherein the secondary insulation material substantially occupies interstitial spaces defined between the dry insulation agglomerates.
 16. The method of claim 10, wherein the step of evaporating the temporary binder from the wetted insulation granules is performed at least by heating the wetted insulation granules.
 17. The method of claim 10, wherein the wetted insulation granules and the dry insulation agglomerates are substantially the same size.
 18. An insulating structure, the insulating structure comprising: a structural envelope having an exterior surface and an interior surface that defines an insulating cavity, wherein the insulating cavity defines an at least partial vacuum; dried silica-based agglomerates that are disposed within the insulating cavity, wherein each agglomerate of the dried silica-based agglomerates includes a silica-based powder insulation material that is water-densified using a temporary binder that includes at least water, the dried silica-based agglomerates being substantially free of the temporary binder; and a secondary insulation material that is disposed within interstitial spaces defined between the dried silica-based agglomerates, wherein the dried silica-based agglomerates define an interior structure that resists inward compressive forces exerted as a result of the at least partial vacuum defined within the insulating cavity.
 19. The insulating structure of claim 18, wherein each agglomerate of the dried silica-based agglomerates is in direct engagement with at least one adjacent agglomerate of the dried silica-based agglomerates.
 20. The insulating structure of claim 18, wherein the secondary insulation material is at least one of a silica-based material, insulating gas, perlite, glass microspheres, and an opacifier. 